Hard surfacing material



Feb. 27, 1962 R. D. WASSERMAN ETAL 3,023,130

HARD SURFACING MATERIAL Filed Aug. 6, 1959 DISCRETE REFRACTORY 201 1421)CARBIDE PARTICLES INVENTORS V RENE D.MSSERMAN JOSZ'PIFFQ UAss ATTORNEYSto the base metal. porates very hard alloying agents such as cobalt,molyb- Uited States Patent 3,023,130 Patented Feb. 27, 1962 Free3,023,130 HARD SURFACING MATERIAL Rene D. Wasserman, Stamford, Conn.,and Joseph F.

Quaas, Island Park, N.Y., assignors to Eutectic Welding AlloysCorporation, Flushing, N.Y., a corporation of New York Filed Aug. 6,1959, Ser. No. 831,937 Claims. (Cl. 117205) This invention relates to amaterial which deposits a hard surface upon a base metal, and moreparticularly relates to such a material which incorporates refractorycarbide hard particles bound within a matrix metal.

Hard surfacing materials are widely used at present for applying a hardsurface to a base metal to protect this base metal from abrasive wear.These surfaced metals are, for example, used to provide wear-resistantsurfaces for tools which are subjected to severe abrasive wear in usesuch as hand and power shovels, and various types of cutting tools.

A widely used type of surfacing material of this kind incorporates hardparticles such as refractory carbides held within a matrix whichmaintains them firmly bound One type of such matrix metal incordenum orvanadium or the like, as described in US. Letters Patent No. 2,280,223.Another type of matrix metal currently in use is a softer material, forexample, a copper base alloy. These types of matrix metals have beenchosen in accordance wth two of the presently accepted theoriesconcerning the desired properties of hard surfacing materials. Hardermatrices themselves enhance the toughness of the deposited material, andthe softer matrix metals mainly are chosen for their ability to securehard particles to the base metals. Since the softer materials wear awayquite readily, the harder surfaces of the particles are maintainedexposed, which is particularly advantageous in conjunction with surfacecutting tools. The hard overlays deposited by these types of matrixmaterials have been reasonably successful for particular applicationscompatible with their specifice properties. However, they have not beenas universally resistant to wear, abrasion, corrosion, heat and impactover widely varying conditions of use as might be desired. a

An object of this invention is to accordingly provide a hard surfacingmaterial which is unusually resistant to wear, abrasion, corrosion, heatand impact over a wide variety of service conditions.

In accordance with this invention, a hard surfacing materialincorporates refractory carbide hard particles bound within a matrixwhich consists essentially of a stainless steel composition having achromium content ranging from 10 to 32 parts by weight and a nickelcontent ranging from 1 to parts by weight. This matrix is remarkablyadherent both to the common base metals and to refractory hard particlessuch as tungsten carbide particles. Furthermore, their deposited overlayis remarkably resistant to wear, abrasion, corrosion, heat and impactfor reasons that are not completely understood. However, the toughnessand ductility of this type of matrix might contribute to itseifcctivenes without impairing the ability of the hard particles tofunction as remarkably effective cutting agents without undue generationof heat. The hard particles may be associated in a rod or electrode withthe matrix by incorporation in a flux coating or by insertion within atube made of the matrix metal.

Novel features and advantages of the present invention will becomeapparent to one skilled in the art from a reading of the followingdescription in conjunction with the accompanying drawings whereinsimilar reference characters refer to similar parts and in which:

FIG. 1 is a perspective view of one embodiment of this invention;

FIG. 2 is a perspective view of another embodiment of this invention;

FIG. 3 is a cross-sectional view taken through FIG. 1, along the line3-3, and;

FIG. 4 is a perspective view of another embodiment of this invention.

FIG. 5 is a cross sectional view of valve stem with a coating as formedby the invention.

One extremely effective form of this invention incorporates a stainlesssteel matrix metal composition which consists essentially of thefollowing formulation in parts by weight:

Constituent Proportional Preferred range example 05/. 20 0. 12 0. 50/2.00 1. 25 1 2. 00 0. 50 0 10/4. 00 0. 50 O3 0. 015 030 0. 020 10.00132.00 31.00 1. 00/20. 00 9.00 Balance Balance 1 Maximum.

Refractory hard carbide particles ranging in particle size, for example,from 10 to 325 mesh are associated with this matrix. This association asshown in FIGS. 1 and 3 is, for example, accomplished by interminglingcarbide particles 10 such as tungsten carbide of the recited particlesize within a flux coating 12 deposited upon. a rod 14 formed of theaforementioned stainless steel matrix composition. This coating is, forexample, formed of one of the alkaline earth compositions described inU.S. Letters Patent 2,820,725 such as the following composition, and asmuch as 60% by weight of this coating may be formed of theaforementioned hard particles.

A particular example of an effective embodiment of this inventionincludes the foregoing preferred matrix and flux compositionsincorporating 40% of tungsten carbide particles of 40 to mesh with thecore rod being .1875 inch in diameter, and the coating being .270 inchin radial thickness.

Instead of tungsten carbide the refractory carbide particles may also beadvantageously made of other formulations such as silicon, chromium,titanium and other similar carbides. 'Ihis surfacing material isremarkably adherent to a wide variety of base metals such as varioussteels including mild, low alloys, medium carbon, freemachining andmanganese steels. Furthermore, other types of metals such as stainlessalloys, copper and copper alloys are also effectively surfaced. When arod .formed of the aforementioned composition is used to coat or surfacea base metal, it imparts unexpectedly high resistance to corrosion,heat, abrasion and wear. Furthermore, the deposited surface material hasunusually effective resistance to impact over a wide temperature rangeincluding very high, normal and sub-zero temperatures. This universalability of the matrix material to function effectively over a widevariety of service conditions is remarkable in comparison to the ratherlimited serviceability of heretofore utilized hard surfacingcompositions.

The aforementioned type of hard surfacing rod may also be effectivelyformed as shown in FIG. 2 by shaping a strip of the matrix metalcomposition as a cylindrical tube 16, and filling it with a flux 18 ofthe aforementioned composition incorporating the previously mentionedhard particle content 20. This tube is made, for example, by shaping astrip of the matrix metal into a cylinder on a forming machine and thenfilling it with hard particles and flux. As much as 50% of the formedwire by weight may consist of hard particles. After this strip has beenformed and filled, it is drawn through a finishing die to compact thefinished rod and make it uniform in content. A highly effective tubeformed in this manner will utilize a strip of matrix which ranges, forexample, from .010 inch to .125 inch thick with an initial tubularoutside diameter ranging from 0.0625 inch to .375 and, preferably .020inch thick with a .094 inch initial O.D. After being drawn through thedie, the tube will, for example, range in outside diameter from inch toA inch. A particularly effective example of this embodiment of theinvention is made of a matrix strip .025 inch in thickness formed anddrawn into a tube .094 inch in OD. packed with a mixture of theaforementioned preferred flux composition incorporating 30 to 40% byweight of tungsten carbide particles of 40 to 100 mesh.

This formed wire may be coiled as shown in FIG. 4 and cut into certainspecific weights. These coiled rods may be used in conjunction withautomatic or semi-automatic welding processes. They can also bedeposited by either the open are or the submerged arc process. Flux canbe fed through a hopper together with the alloy wire. Furthermore, thiswire can be deposited by the inert arc process in which inert gases suchas argon, helium and mixtures thereof are used as protective blanketswithin the arc.

A matrix formulation of the type described herein may be deposited byusing a matrix metal of the desired ultimate composition, or it may beprovided by using a stainless steel composition which is deficient tosome extent in a constituent such as chromium which is inserted inpowder form in the required additive amount within a tube formed of achromium deficient matrix alloy of this invention. A tube of this metalmay be accordingly formed of the following composition in parts byweight, and from 15 to 50 parts by weight of metal powder having achromium content which may be, for example, chromium powder orferrochromium powder incorpo- As previously mentioned, up to 50% of theformed wire may consist of this chromium containing metal powder andflux may or may not be also incorporated within the tube. This lattertype of electrode is a relatively economical method of providingdeposited overlays having the remarkably efiective characteristics ofthis invention. A particular example of this type of rod is made in a.similar manner to the tube previously described in which the insertedflux contains, for example,

40% by weight of hard particles, or in which no flux at all is combinedwith the hard particles.

An exceptionally effective application of this hard surfacing materialis, for example, demonstrated as shown in FIG. 5 by building up a layerof this hard surfacing material including matrix metal 24 and hardparticles 26 upon a base 28 of ordinary steel in the form of a forgingdie used for manufacturing a valve stem. This overlay was deposited upona base of ordinary steel of which a small portion including the overlaywas cut off and welded upon a copper base. The resultant die operatedwith remarkable efficiency in forging a valve stem with the heavy copperbase helping to eliminate heat created during the forging operation andcushioning impact forces. Similar tools formerly made of other hardsurfacing materials lasted only a few hours under preheats of as much as900 C. in contrast to the die formed in accordance with this inventionwhich has operated as long as 200 hours under such severe serviceconditions.

What is claimed is:

1. A hard surfacing material comprising a matrix metal consistingessentially of the following formulation in parts by weight Constituent:Range in parts by weight Carbon -Q. .05/.20 Manganese 0.50/2.00 Silicon2.00 max. Molybdenum 0.10/ 4.00 Phosphorus .030 max. Sulfur .030 max.Chromium 1000/3200 Nickel 1.00/ 20.00 Iron Balance and discreterefractory carbide hard particles of 10 to 325 mesh particle sizeranging from 10 to 60% by weight of said matrix metal associated withsaid matrix metal by attachment to a body including said matrix and saidparticles.

2. A hard surfacing material as set forth in claim 1 wherein said hardparticles are made of tungsten carbide.

3. A hard surfacing material as set forth in claim 1 wherein said matrixmetal is provided in the form of a rod, said rod being covered with aflux coating compatible with said matrix metal, and said hard particlesbeing incorporated in said flux coating in an amount up to 60% by weightof said flux coating.

4. A hard surfacing material as set forth in claim 3 wherein said fluxconsists essentially of the following formulation- Constituent:Proportional range Titanium dioxide 20 to 35 Calcium fluoride 5 to 15Calcium carbonate 15 to 25 Bentonite 2 to 8 Iron oxide 5 to 15 Manganeseoxide 2 to 12 Calcium metasilicate 5 to 15 Aluminum oxide 0.5 to 10Potassium titanate 10 to 20 5. A hard surfacing material as set forth inclaim 3 wherein said flux consists essentially of the followingformulation- 6. A hard surfacing material comprising a matrix metalapproximately consisting of the following formulation in parts byweight- Constituent: Parts by weight Carbon .05/.20 Manganese 0.5 0/2.00 Silicon 2.00 max. Molybdenum 0. 4.00 Phosphorus .030 max. Sulfur.030 max. Chromium a- 10.00/ 32.00 Nickel 1.00/ 20.00

Iron Balance and discrete refractory hard carbide particles of 40 to 100mesh in an amount approximately 40% by weight of said matrix metal beingassociated with said matrix metal by attachment to a body including saidmatrix and said particles.

7. A hard surfacing material comprising a matrix metal consistingessentially of the following formulation- Constituent: Percent by weightCarbon 0.08. Chromium 18.0 to 21.00. Nickel 9.0 to 11.00. Manganese2.50. Silicon 0.09. Phosphorus 0.04. Sulfur 0.03. Iron Balance.

6 Constituent: Parts by weight Carbon 0.08. Chromium 18.0 to 21.00.Nickel 9.0 to 11.00. Manganese 2.50. Silicon 0.90. Phosphorus 0.04.Sulfur 0.03.

Iron Balance.

and approximately 40% by weight of said matrix metal of discreterefractory carbide hard particles of 40 to mesh, said matrix metal beingformed into a cylindrical tube, said hard particles being insertedwithin said tube, and chromium metal powder of mesh being insertedwithin said tube with said hard particles, and said metal powder beingpresent in an amount which is approximately 15% by weight of said matrixmetal.

9. A hard surfaced body comprising a base metal, a hard surfacingmaterial deposited upon said base metal, said hard surfacing materialconsisting essentially of the following formulation which is intimatelyinterspersed an amount of discrete refractory carbide hard particlesranging in size from 10 to 325 mesh ranging up to 60% by weight of saidbase metal Constituent: Range in parts by weight Carbon .05 .20Manganese 0.05 2.00 Silicon 2.00 max. Molybdenum 0. 10/ 4.00 Phosphorus.03 0 max. Sulfur .030 max. Chromium 10.00/ 32.00 Nickel 1.00/ 20.00Iron Balance 10. A hard surfaced body as set forth in claim 9 whereinsaid hard particles are tungsten carbide.

References Cited in the file of this patent UNITED STATES PATENTS2,408,619 Friedlander Oct. 1, 1946 2,493,143 Ingels Jan. 3, 19502,632,835 Wasserman Mar. 24, 1953 2,745,771 Pease et a1. May 15, 19562,755,199 Rossheim et a1. July 17, 1956 2,802,756 Bloom Aug. 13, 19572,888,344 Noren May 26, 1959

1. A HARD SURFACING MATERIAL COMPRISING A MATRIX METAL CONSISTINGESSENTIALLY OF THE FOLLOWING IN PARTS BY WEIGHT-